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Companion
Reservoirs
Technical Service Manual
I Preface
Companion Reservoirs
SERVICE MANUAL
Companion Reservoir
CAIRE, Inc.
2200 Airport Industrial Dr., Ste. 500
Ball Ground, GA 30107
www.cairemedical.com
Customer/Technical Service:
North and South America
Phone (US Only): 800-482-2473
US:
770-721-7759
Asia, Australia, Pacific Rim
Phone:
770-721-7759
Europe
Phone:
+44 (0) 1189 367080
Fax: 888-932-2473
Fax: 770-721-7758
Fax: 770-721-7758
Fax: +44 118 9799245
For Customer of Technical Service needs (product assistance, ordering, part numbers, specifications, unexpected events, etc.) contact:
CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500
1-800-482-2473
www.cairemedical.com
NOTE: CAIRE Reservoir and Portable units are intended only for the delivery of medical grade oxygen as prescribed by a
physician.
NOTE: SI pressure values expressed in manual are referenced to atmosphere.
HELiOS™, Companion®, and Liberator are trademarks of CAIRE INC.
SNOOP® is a trademark of the SWAGELOK Co.
Teflon® and Krytox® are trademarks of E. I. DUPONT DE NEMOURS & Co.
Kel-F® and Scotch-Brite™ are trademarks of the 3M Co.
Magnehelic® is a trademark of the DWYER INSTRUMENT Co.
QUICK-GRIP® is a trademark of the AMERICAN TOOL Co.
Sporicidin® is a trademark of SPORICIDIN INTERNATIONAL.
Disclaimer
This manual is intended for use by experienced personnel only. No attempt should be made to fill or maintain this equipment until both this
manual and the Patient Operating Instruction booklet have been read and fully understood.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
1
I Preface
Companion Reservoirs
Abbreviations
FCV Flow Control Valve
LED Light Emitting Diode
LOX Liquid Oxygen
LPM Liters Per Minute
NER Normal Evaporation Rate
POI Patient Operating Instructions
N2 Nitrogen Gas
TF Top Fill
DF Dual Fill
DISS Diameter Index Safety System
PRV
QDV
RMA
RP
RR
SRV
O2
SF
PTFE
Primary Relief Valve
Quick Disconnect Valve
Return Materials Authorization
Repair Procedure
Removal and Replacement
Secondary Relief Valve
Oxygen Gas
Side Fill
Polytetrafluoroethylene (“Teflon”)
Definition of Terms
WARNING Description of a condition that can result in personal injury or death.
CAUTION Description of a condition that can result in equipment or component damage.
NOTE
A statement containing information important enough to emphasize or repeat.
(ITEM)
Item numbers used throughout this manual are shown on the illustrations beginning on page 34.
Definition of Product Symbols
Table 1: Definition of Product Symbols
Symbol
Definition
Symbol
Read instruction manual
The unit contains liquid oxygen
which is extremely cold, almost
-300°F. Exposure to such a low temperature can cause severe frostbite.
Do not touch frosted parts
Liquid and gaseous oxygen are nonflammable. However, they cause
other materials to burn faster than
normal. This hazard, along with the
low temperatures of liquid oxygen,
warrants certain safety precautions.
Do not smoke near unit or while operating unit
Definition
Name and address of manufacturer
Authorized representative in the
European Community
or
Caution, consult accompaning documents
Non-flammable gas
Oxidizing substances
Portable Full
Keep unit well ventilated at all times
Portable Empty
Keep unit in upright position
For use by doctor’s prescription
only.
Drip Proof
Type BF (Electrical Safety)
WEEE and RoHS
This symbol is to remind the
equipment owners to return it to a
recycling facility at the end of its life,
per Waste Electrical and Electronic
Equipment (WEEE) Directive.
Our products will comply with the
restriction of Hazardous Substances
(RoHS) directive. They will not contain more than trace amounts of lead
or other hazardous material content.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
2
II
1 Table of Contents
I.Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
II. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III.Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IV. Equipment Description . . . . . . . . . . . . . . . . . . . . . 10
V. Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 11
Companion Reservoirs
VI.Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
VII. Saturation Principles. . . . . . . . . . . . . . . . . . . . . . . 15
VIII. Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . . 17
IX.Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
X.Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
XI. Troubleshooting & Repair Procedures . . . . . . . . . 24
XII. Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
XIII. Ordering Information. . . . . . . . . . . . . . . . . . . . . . . 40
XIV. Return & Restocking Policy. . . . . . . . . . . . . . . . . . 41
XV. Service Tools/Equipment/Supplies. . . . . . . . . . . . 42
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
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III Safety
Oxygen, as it exists at standard atmospheric pressure and temperature, is a colorless, odorless, and tasteless gas. Oxygen constitutes 21% of the atmosphere, by volume. Aside from its welldocumented ability to sustain life, oxygen also supports combustion, even though it is nonflammable. Many substances which
will burn in air, burn at a faster rate and at a higher temperature in
an oxygen enriched atmosphere. Other materials that do not burn
in air will burn as oxygen concentration increases. Additionally,
many greases and liquid solvents become extremely hazardous
materials when placed in an oxygen-enriched environment. In its
liquid form, oxygen is still odorless and tasteless, but is pale blue
in color. At an operating pressure of 1,4 bar /20 psig, the temperature of liquid oxygen is about -173°C/-280° F. Skin exposed
to such a low temperature can become severely frostbitten.
Contraindications
While CAIRE, Inc. equipment is designed and built to the most
rigid standards, no piece of mechanical equipment can ever be
made 100% foolproof. Strict compliance with proper safety practices is necessary when using any CAIRE unit. We recommend
that our distributors emphasize safety and safe handling practices
to their employees and customers. While safety features have
been designed into the unit and safe operations are anticipated, it
is necessary that all distributor personnel carefully read and fully
understand WARNINGS, CAUTIONS, and NOTES throughout
the manual. Periodic review of this information is recommended.
These hazards require certain safety precautions to be taken when
working around gaseous and/or liquid oxygen.
WARNING: Never permit combustible substances such as
greases, oils, solvents, or other compounds not oxygen compatible to contact any component of the unit exposed to higherthan atmospheric concentrations of gaseous or liquid oxygen.
This especially applies to tubing, fittings, and valves.
WARNING: Keep oxygen equipment away from open flames
or electrical appliances such as heaters, stoves, toasters, and
other devices with heating elements.
WARNING: Never permit smoking in an area where oxygen
equipment is repaired, filled, or used.
WARNING: Always wear goggles, a face shield, and insulated
gloves when working with or around liquid oxygen.
WARNING: Do not modify equipment without authorization
from the manufacturer.
WARNING: These devices are not intended for life supporting
applications nor do they provide patient monitoring capabilities.
WARNING: In certain circumstances, the use of non-prescribed oxygen can be hazardous. These devices should only
be used when prescribed by a physician.
WARNING: Not for use in the presence of flammable anesthetics.
CAUTION: All CAIRE reservoir units should be moved by utilizing the roller base or hand truck. Do not roll units on their
side or edge as insulation damage can occur. All CAIRE reservoir units must be used, stored, and transported in a vertical
position. Do not lay, store, or ship on its side.
Companion Reservoirs
Safety Guidelines and Operational Safety
WARNING: Excess accumulation of oxygen creates an
oxygen-enriched atmosphere (defined by the Compressed Gas
Association as an oxygen concentration above 23%). In an
oxygen-enriched atmosphere, flammable items may burn vigorously and may explode. Certain items considered noncombustible in air may burn rapidly in such an environment. Keep all
organic materials and other flammable substances away from
possible contact with oxygen; particularly oil, grease, kerosene,
cloth, wood, paint, tar, coal dust, and dirt which may contain oil
or grease. DO NOT permit smoking or open flame in any area
where oxygen is stored, handled, or used. Failure to comply
with this warning may result in serious personal injury.
WARNING: In the event a unit is dropped, tipped over, or
unreasonably abused, immediately, but cautiously, raise the
container to its normal vertical position. If substantial container damage has occurred, remove the liquid oxygen from
the vessel in a safe manner (RP3). Purge the unit with an inert
gas (nitrogen) and promptly return it to CAIRE for inspection.
The container should be prominently marked “CONTAINER
DROPPED, INSPECT FOR DAMAGE.” Failure to comply
with these procedures may result in personal injury and can seriously damage the container.
WARNING: Personnel must remove liquid oxygen and depressurize the unit before removing parts or loosening fittings from
a unit. Failure to do so may result in personal injury from the
extreme cold of liquid oxygen and/or the pressure in the vessel.
WARNING: During transfer of liquid oxygen, components will
become extremely cold. Care should be used to avoid any contact with these components, as serious frostbite may result.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
4
III Safety
WARNING: The possibility of fire exists when the combination of a fuel, source of ignition, and oxygen is present. High
concentrations of oxygen (air is approximately 21% oxygen)
greatly enhance the possibility of combustion.
NOTE: Figure 1 below is referred to as the fire/combustion triangle. This triangle describes the three factors required for fire/
combustion to occur.
WARNING: During transfer of liquid oxygen gas blow off
from the vent valve creates a loud horn-like noise. Ear protection is recommended.
WARNING: Extreme high pressure can rupture container or
plumbing components. Be sure specified pressure relief devices
are present, in the proper location, and functioning properly.
NOTE: Liquid oxygen at atmospheric pressure expands at a
ratio of approximately 860:1 (at 0 bar/ 0psig) when vaporizing
into a gas. This can occur very rapidly when exposed to the
heat in the atmosphere. See Figure 2 for comparison.
Companion Reservoirs
WARNING: When using concentrated oxygen, the risk of fire
is increased.
GAS
LOX
Figure 1: Fire/Combustion Triangle
NOTE: To reduce the risk of combustion/fire when dealing
with LOX, please refer to the following suggestions
1
860
Figure 2: LOX to Gas ratio
• Obtain all replacement parts for medical oxygen equipment
from the manufacturer.
WARNING: Do not smoke or keep burning tobacco near this
equipment. Death or injury may occur.
• Use only recommended oxygen compatible cleaning and
leak detection products.
WARNING: Keep flammable materials away from this equipment. Oils, grease, including facial creams and petroleum jelly,
asphalt, and synthetic fibers ignite easily and burn rapidly in
the presence of concentrated oxygen. If needed, use only specified oxygen compatible lubricants as directed.
• Keep the reservoir upright at all times. Secure liquid oxygen equipment when transporting to prevent accidental
tipover and spillage.
• If a liquid oxygen spill occurs indoors, open doors and
windows to ventilate the area. Avoid sources of ignition
and do not walk on or roll equipment over the affected
area.
• Any clothing or porous material that is splashed with liquid oxygen or otherwise absorbs high concentrations of
oxygen should be removed and aired for at least one hour
away from any source of ignition.
WARNING: Liquid oxygen vessels periodically release small
amounts of oxygen gas that must be ventilated to prevent pressure buildup. Do not store liquid oxygen equipment in a car
trunk, closet, or other confined area. Do not place bags, blankets, draperies, or other fabrics over the equipment when it
contains liquid oxygen.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
5
III Safety
WARNING: The use of Accessories, transducers, and cables other
than those specified by the manufacturer may result in increased
Emissions or decreased immunity of the Companion Reservoir.
WARNING: Portable and mobile RF communications equipment
can affect Medical Electrical Equipment.
WARNING: The Companion Reservoir should not be used adjacent to or stacked with other equipment, and that if adjacent or
stacked use is necessary, the Companion Reservoir should be observed to verify normal operation in the configuration in which it
will be used.
Table 2
Companion Reservoirs
WARNING: Medical electrical Equipment needs special precautions regarding EMC and needs to be installed and put into service
according to the EMC information provided in this manual.
Guidance and Manufacturer’s declaration—electromagnetic emissions
The Companion Reservoir is intended for use in the electromagnetic environment specified below. The customer or the user of the
Companion Reservoir should assure that it is used in such an environment.
Emissions test
Compliance
RF emissions
CISPR 11
Group 1
Electromagnetic environment—guidance
The Companion Reservoir uses RF energy only for internal function.
Therefore, its RF emissions are very low and are not likely to
cause any interference in nearby electronic equipment.
RF emissions CISPR 11
Harmonic emissions The Companion Reservoir is suitable for use in all establishments, IEC 61000-3-2
including domestic establishments and those directly connected to
Class B
Not applicable
Voltage fluctuations/
the public low-voltage power supply network that supplies buildings flicker emissions used for domestic purposes.
IEC 61000-3-3
Not applicable
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
6
III Safety
Guidance and manufacturers declaration—electromagnetic immunity
The Companion Reservoir is intended for use in the electromagnetic environment specified below. The customer or the user of the
Companion Reservoir should assure that it is used in such an environment.
Immunity test
Electrostatic discharge (ESD) IEC 60601 test level
Compliance level
±6 kV contact
±6 kV contact
±8 kV air
±8 kV air
Electromagnetic environment—guidance
Floors should be wood, concrete or ceramic tile. If floors
are covered with synthetic material, the relative
IEC 61000-4-2
humidity should be at least 30%.*
Electrical fast ±2 kV for power
Not applicable
Not applicable
transient/burst supply lines
DC powered device
IEC 610004-4
±1 kV for Surge IEC 61000-4-5
Not applicable
input/output lines No data input/output lines
±1 kV line(s)
to line(s)
Not Applicable
±2 kV line(s)
DC powered device
<5% UT (>95% dip
short interruptions in UT) for 0,5 cycle
and voltage 40% UT (60% dip
variations on in UT) for 5 cycles
Not Applicable
power supply 70% UT (30% dip
DC powered device
input lines in UT) for 25 cycles
IEC 61000-4-11
<5% UT (>95% dip
Power frequency
(50/60 Hz)
magnetic field
Not Applicable
to earth
Voltage dips, Companion Reservoirs
Table 3
Not Applicable
in UT) for 5 sec
3 A/m
3 A/m
Power frequency magnetic fields should be at levels
characteristic of a typical location in a typical
commercial or hospital environment.
IEC 61000-4-8
Note: UT is the a.c. mains voltage prior to application of the test level.
* This statement indicates that the required testing was performed in a controlled environment and the Companion Reservoir are found
to be compliant with regulations.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
7
III Safety
Guidance and manufacturers declaration—electromagnetic immunity
The Companion Reservoir is intended for use in the electromagnetic environment specified below. The customer or the user of the
Companion Reservoir should assure that it is used in such an environment.
Immunity test
IEC 60601 test level Compliance level
Conducted RF 3Vrms
Not Applicable
IEC 61000-4-6
150kHz to 80 MHz
Battery powered
device
Radiated RF
3 V/m
3 V/m
IEC 61000-4-3
80 MHz to 2,5 GHz
Electromagnetic environment—guidance
Portable and mobile RF communications equipment should
be used no closer to any part of the Companion Reservoir,
including cables, than the recommended separation distance
calculated from the equation applicable to the frequency
of the transmitter.
Recommended separation distance
d = 1.2 √P
d = 1.2 √P 80 MHz to 800 MHz
d = 2.3 √P 800 MHz to 2,5 GHz
Field strengths from fixed RF transmitters, as determined
by an electromagnetic site surverya, should be less than
the compliance level in each frequency rangeb.
Interference may occur in the vicinity of equipment marked
with the following symbol:
Companion Reservoirs
Table 4*
where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter
manufacturer and d is the recommended separation
distance in meters (m).
NOTE 1 At 80 MHz and 800 MHz, the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection from
structures, objects and people.
a
Field strengths from fixed transmitters, such as base stations for radio (cellular/cordless) telephones and land mobile radios, amateur radio, AM and FM radio broadcast and TV broadcast cannot be predicted theoretically with accuracy. To asses the electromagnetic environment due to fixed RF transmitters, an electromagnetic site survey should be considered. If the measured field strength
in the location in which the Companion Reservoir is used exceeds the applicable RF compliance level above, the Companion
Reservoir should be observed to verify normal operation. If abnormal performance is observed, additional measures may be necessary, such as reorienting or relocating the Companion Reservoir.
b
Over the frequency range 150 kHz to 80 MHz, field strengths should be less than 3 V/m.
* This table is included as a standard requirement for equipment which has been tested to specific test levels and over specific
frquency ranges and been found compliant with regulations.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
8
III Safety
Recommended separation distances between portable and mobile
RF communications equipment and the Companion Reservoir
The Companion Reservoir is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled.
The customer or the user of the Companion Reservoir can help prevent electromagnetic interference by maintaining a minimum
distance between portable and mobile RF communications equipment (transmitters) and the Companion Reservoir as recommended
below, according to the maximum output power of the communications equipment.
Rated maximum outputSeparation distance according to frequency of transmitter
power of transmitter W
150 kHz to 80 MHz
m
Companion Reservoirs
Table 5*
80 MHz and 800 MHz 800 MHz to 2,5 GHz
d=1.2√P
d=1.2 √P
d=2.3 √P
0,01
0.12 m
0.12 m
0.23 m
0,1
0.38 m
0.38 m
0.73 m
1
1.2 m
1.2 m
2.3 m
10
3.8 m
3.8 m
7.3 m
100
12 m
12 m
23 m
For transmitters rated at a maximum output power not listed above, the recommended separation distance (d) in meters (m) can
be estimated using the equation applicable to the frequency of the transmitter, where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter manufacturer.
NOTE 1 at 80 MHz and 800 MHz, the separation distance for the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection from
structures, objects and people.
* This table is included as a standard requirement for equipment which has been tested to specific test levels and over specific
frquency ranges and been found compliant with regulations.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
9
IV Equipment Description
Top Cover
1. Cryogenic Container This assembly is a double walled
vacuum insulated Dewar for storing liquid oxygen (LOX) at
approximately -173°C/-280°F. The inner vessel is designed
to safely hold liquid oxygen and is protected from over pressurization by the primary relief valve. Vacuum insulation
between the inner and outer vessel keeps outside heat from
causing the cold liquid inside to evaporate.
Shroud
2. Plumbing System The plumbing system consists of the
warming and breathing coils, vent valve, R/E valve, SRV,
high and low pressure lines, pressure gauge (European units
only), FCV and QDV (fill connector).
Fill Connector
Vent Valve
Pressure Gauge
Contents Indicator
Pop-Off Actuator
Low Pressure
Sense Line
Breathing Coil
SRV**
R/E Valve**
FCV
Humidifier Adaptor
PRV Outlet**
Plumbing Manifold**
The CAIRE Companion Reservoir units are the stationary components in a liquid oxygen system. The Companion Reservoir
incorporates a stainless steel cryogenic container with the
valves, plumbing, and associated hardware required to deliver
gaseous oxygen to the patient at near ambient temperature. The
Companion Reservoir is comprised of four major assemblies,
grouped according to function.
Companion Reservoirs
Figure 3: Companion reservoirs components
Vacuum Port
Warming Coil
3. Shroud Assembly The reservoir unit’s shroud assembly includes a shroud and top cover. The shroud is made of durable plastic and designed to protect the internal components
of the plumbing system.
High Pressure
Sense Line
Serial Number
Identification Label
Condensate
Bottle
Condensation Ring
Cryogenic Container
4. Liquid Content/Level Indicator This system uses differential
pressure to measure the level of LOX remaining in the cryogenic vessel and displays the level with an integral indicator
that is viewed through the top cover. The liquid contents are
indicated by aligning the colored line on the piston with the
graduated markings on the cylinder.
* = Units manufactured for sales in Europe (TPED) contain an
internal pressure gauge. Please contact Technical Service with
any questions regarding unit identification.
** = Units manufactured for sales in Europe (TPED) and/or units
manufactured after June 2011 will have a “3 Port” manifold design. These units will also contain an internal pressure gauge and
an R/E valve assembly. Please contact Technical Service with
any questions regarding unit identification.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
10
V Theory of Operation
As in all vacuum-insulated cryogenic containers, some liquid
(oxygen in this case) is always evaporating into a gas. The rate
of generation of this gas, with the flow control valve closed, is
called the normal evaporation rate (NER). This gas is lost through
the primary relief valve.
WARNING: Low oxygen flow rates to the patient may result
if CAIRE reservoirs are filled with improperly saturated liquid
oxygen.
WARNING: The vent valve orifice does not guarantee properly
saturated LOX. The filling source tank must have a minimum
2,4 bar/35 psig (optimum 3,4 bar/50 psig) to transfill into
CAIRE reservoirs or low saturation will occur.
When the FCV is at any setting other than off, and the economizer valve is open (pressure over 1,3 bar/19.5 psig), gaseous oxygen is forced from the head space in the inner vessel,
through the economizer valve, to the warming coil and breathing
coil. This process conserves or “economizes” liquid oxygen by
withdrawing the head gas first, instead of allowing it to escape
through the relief valve. While flowing through the breathing
coil, the cold gaseous oxygen is warmed to near-ambient temperature before being metered and dispensed by the flow control
valve. Whenever gas is removed from the space above the liquid
oxygen (head space), the inner vessel internal pressure begins to
drop slightly. When the pressure drops to 1,3 bar/19.5 psig, the
economizer valve closes, forcing liquid oxygen up the withdrawal
tube, through the bypass tee and through the warming coil where
it becomes gas, then through the FCV, providing gaseous oxygen
to the patient.
Companion Reservoirs
The Companion reservoir provides a source of liquid oxygen to
fill portable units. It also provides gaseous oxygen to a patient
through the 12 position, 0-10 LPM FCV. If all reservoir outlets
are closed (Vent Valve, PRV, SRV, FCV, QDV) with LOX in
the unit, then the pressure in the inner vessel will remain near the
primary relief valve setting of less than 1,7 bar/25 psig.
NOTE: In Figure 5, the operating pressure is at or below
1,3 bar/19.5 psi.
NOTE: In Figure 4, the operating pressure is above
1,3 bar/ 19.5 psi.
Figure 4
Gas
Gas
Liquid
Liquid
Figure 5
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
11
V Theory of Operation
Companion Reservoirs
Liquid Contents/Level Indicator Operation
The contents indicator, visible through the top cover of the reservoir, measures and displays the amount of liquid oxygen remaining in the Companion reservoir. It consists of a moveable piston/
rolling diaphragm assembly that is sealed within a plastic cylinder. The system is based on the principle that the pressure created
at the bottom of a tank of liquid is proportional to the height of
the liquid. The pressure signal is also a function of gaseous headspace pressure acting on the top of the liquid. A differential pressure between the liquid and the headspace gas causes the piston
to move in the cylinder a distance proportional to the amount of
liquid oxygen in the container. The liquid oxygen contents are indicated by aligning the colored line on the piston with the graduated markings on the cylinder.
Internal Pressure Gauge Operation (If Equipped)
The pressure indicator is a bourdon tube pressure gauge that indicates the status of the system pressure in the head space. The indicator is not calibrated in units of pressure. However, a dark blue
shaded region on the indicator dial marks an acceptable operating
pressure range of approximately 1.0-1.7 bar/15-25 psig. The pressure indicator is used to evaluate the reservoir system headspace
pressure during a fill and during system operation. The pressure
indicator does not indicate oxygen outlet pressure.
Figure 6
2.0
CAIRE
xx
xx
xx
Rev
A
1.1 bar
USE NO OIL
xx
60 psi
Figure 7
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
12
IV Equipment Description
Each Companion reservoir is identified by a unique serial number. For reservoirs manufactured prior to January 1985, the number begins with a single digit signifying the year of manufacture,
followed by digits signifying the month of manufacture, followed
by digits signifying the calendar day of manufacture, and ends
with digits signifying the unit’s production number for that day.
For reservoirs manufactured between January 1985 and
October 1994, the number begins with a double digit signifying
the year of manufacture, followed by digits signifying the month
of manufacture, followed by digits signifying the calendar day of
manufacture, and ends with digits signifying the unit’s production number for that day.
For reservoirs manufactured in and after October 1994, the
number begins with a double digit signifying the year of manufacture, followed by digits signifying sequential day of the year
on which the unit was manufactured, and ends with digits signifying the unit’s production number for that day.
For reservoirs manufactured after June 2010, the number
begins with the letters CB signifying the manufacturing location,
followed by the reservoir product code B30, followed by digits
signifying the year of manufacture, followed by a two digit number to signify the week of the year that the unit was manufactured
and ends with digits signifying the unit’s production number for
that week.
For all units manufactured prior to June 2010, the serial
number is etched handle of the cryogenic container. For units
manufactured after June 2010, a label containing the serial number is placed on or above the handle of the reservoir. This Serial
Number is crucial if a problem arises with the unit or if support
is ever needed through CAIRE Customer Service or Technical
Service.
Figure 8
Reservoirs Manufactured prior to January 1985
4 - 6 - 25 - 1
Designates Year Designates
Month
(4 represents
1984)
Designates Day Designates Number
of Month
of Specific Unit
Produced that Day
Reservoirs Manufactured in and after January 1985
and prior to October 1994
Companion Reservoirs
Reservoir Serial Number Identification
88 06 25 01
Designates Year Designates
Month
Designates Day Designates Number
of Month
of Specific Unit
Produced that Day
Containers Manufactured in and after October 1994
95 176 001
Designates Year
(4 represents
1984)
Designates Sequential Day
of Year
(Jan 1 = 001, Dec 31 = 365)
Designates Number
of Specific Unit
Produced that Day
Reservoirs Manufactured after June 2010
CB B30 10 29 0964
Designates
Designates
Manufacturing Reservoir
Product
Location
Code
Designates Designates Designates
Year
Day of
Number
Month
of Specific
Unit
Produced
that Week
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
13
VI
1 Specifications
COMPANION RESERVOIR SPECIFICATIONS
MODEL
C21
C31
C41
21 liters/.74 ft3
31 liters/1.10 ft3
41 liters/1.45 ft3
Weight of LOX @ 1,7 bar/24
psig Saturation (typical)
22 kg/49 lbs
33 kg/73 lbs
44 kg/98 lbs
Gaseous Oxygen Equivalent @
1 atm. And 21°C/70°F
16,750 liters /591.4 ft3
24,950 liters /881 ft3
33,500 liters /1182 ft3
Height
69.9 cm/27.5 in
83.8 cm/33.0 in
97.8 cm/38.5 in
Diameter
36.2 cm/14.25 in
36.2 cm/14.25 in
36.2 cm/14.25 in
Empty Weight
20.0 kg/45 lbs
23.0 kg/51 lbs
27.0 kg/60 lbs
Full Weight
42.0 kg/94 lbs
56.0 kg/124 lbs
71 kg/158 lbs
Outlet Pressure
1,3 bar/19.5 psig
1,3 bar/19.5 psig
1,3 bar/19.5 psig
Economizer Pressure
1,3 bar/19.5 psig
1,3 bar/19.5 psig
1,3 bar/19.5 psig
Less than 1,7 bar/25 psig
Less than 1,7 bar/25 psig
Less than 1,7 bar/25 psig
­Volume of LOX (typical)
Primary Relief Valve Opening
Pressure
Primary Relief Valve Reseat
Pressure
Secondary Relief Valve
Opening Pressure
Companion Reservoirs
Table 6
Greater than 1,4 bar/21 psig Greater than 1,4 bar/21 psig Greater than 1,4 bar/21 psig
2,1 bar/30 psig
+/- 5%
2,1 bar/30 psig
+/- 5%
2,1 bar/30 psig
+/- 5%
Secondary Relief Valve Reseat
Greater than 1,9 bar/27 psig Greater than 1,9 bar/27 psig Greater than 1,9 bar/27 psig
Pressure
Normal Evaporation Rate
(NER) (typical)
Maximum Outlet Flow
Contents Indicator
0.73 - 0.95 kg /
1.6 - 2.1 lbs per day
.73 - 1.0 kg/
1.6 - 2.2 lbs per day
.73 - 1.0 kg/
1.6 - 2.2 lbs per day
10 L/min
10 L/min
10 L/min
Mechanical, Differential
Pressure Based
Mechanical, Differential
Pressure Based
Mechanical, Differential
Pressure Based
Operating Temperature
10°C to 40°C/50°F to 104°F 10°C to 40°C/50°F to 104°F 10°C to 40°C/50°F to 104°F
95% max. relative humidity 95% max. relative humidity 95% max. relative humidity
Storage Temperature
-40°C to 70°C/-40°F to
-40°C to 70°C/-40°F to
­-40°C to 70°C/-40°F to
158°F
158°F
158°F
90% max. relative humidity 90% max. relative humidity 90% max. relative humidity
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
14
VII
1 Saturation Principles
Oxygen, like most gases, will condense into a liquid with an increase in pressure or decrease in temperature. As a liquid, oxygen is
pale blue in color and is about 860 times as dense as its gaseous form. At atmospheric pressure (14.7 psia), oxygen condenses into its
liquid form at a temperature of about -297°F (-184°C). Liquid oxygen (LOX) is an efficient form of oxygen to meet a patient’s portable, ambulatory oxygen needs. A volume of liquid oxygen, when vaporized, yields about 860 volumes of gaseous oxygen (Figure 2).
As you can see, a relatively small volume of liquid oxygen provides a much larger volume of gaseous oxygen for a patient to use.
In medical liquid oxygen systems, liquid oxygen, and the gaseous oxygen resulting from its vaporization or boiling, is stored under
pressure. The elevated pressure, typically 22 psig (152 kPa), enables oxygen to flow to the patient at a selected, prescribed rate. To
sustain this oxygen flow to the patient, the liquid oxygen must be in a state that allows vaporization to readily occur. In other words,
the liquid oxygen must be in a state of saturation. Let’s take a look at what liquid saturation is all about.
Companion Reservoirs
Oxygen, in its normal state, is a colorless, tasteless, and odorless gas that is non-flammable, although it greatly accelerates combustion
in high concentrations. It constitutes about 21% of the Earth’s atmosphere by volume. Oxygen in higher concentrations is medically
beneficial to patients suffering from certain respiratory diseases.
A saturated liquid is one that absorbs the maximum amount of heat possible at a given pressure without vaporizing into a gas. If additional heat is added, the saturated liquid begins to vaporize (boil) while remaining at a constant temperature until all of the liquid
is vaporized. A common example of a saturated liquid is water at its boiling point of 212°F (100°C) at sea level. The constant addition of heat to the boiling water does not cause it to become hotter, but instead causes part of the liquid water to turn to water vapor
(Figure 9).
Figure 9: Saturated (Boiling) Water at Sea Level
The saturation (boiling) point of a liquid depends not only on temperature but also on pressure. If the pressure in a container of saturated liquid increases, the temperature required for saturation to occur will also increase. This leaves the liquid unsaturated, that is,
capable of accepting more heat before it will boil (Figure 10).
Figure 10: Saturated (Boiling) Water at Higher Pressure
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
15
VII
1 Saturation Principles
Companion Reservoirs
If the pressure in a container of saturated liquid decreases, the temperature required for saturation to occur will decrease. This leaves
the liquid “super saturated” or too warm. When this occurs, rapid boiling and vaporizing of some of the liquid occurs. The rapid boiling and evaporation of the liquid dissipates the excessive heat until the remaining liquid cools down to the new saturation temperature
associated with the decreased pressure (Figure 11).
Figure 11: Saturated (Boiling) Water at Lower Pressure
Oxygen, which is normally a gas at atmospheric pressure, changes into liquid form when it is cooled to about -297°F (-183°C) at
atmospheric pressure. It is saturated at this temperature (and pressure) which means it will remain a liquid as long as no additional
heat is added. However, the large quantity of heat present in the atmosphere constantly enters the liquid oxygen and causes it to boil
and vaporize back into a gas. Since it is virtually impossible to keep all of the heat in the atmosphere from entering the liquid oxygen,
constant boiling and vaporization occurs.
Now when liquid oxygen is placed in a closed container, the vaporizing gas is trapped and begins to build pressure. As pressure increases above atmospheric pressure, more heat is needed for boiling to occur at the higher pressure. The heat that is constantly available from the atmosphere warms the liquid to a higher temperature where boiling again occurs. The vaporizing gas builds pressure
and the process continues. As the pressure on liquid oxygen builds, the related saturation temperature of the liquid increases proportionally (Figure 12).
Figure 12: Liquid Oxygen Saturation Curve
It is important to maintain liquid oxygen saturation (boiling) at the specified operating pressure of the system. As an oxygen flow
demand is put on the system, a slight decrease in pressure occurs due to oxygen withdrawal. The saturated liquid oxygen in the system vaporizes enough gaseous oxygen to maintain system operating pressure. This ensures proper oxygen flow to the patient. If the
liquid oxygen saturation temperature is too low, the corresponding lower saturation pressure causes low oxygen flows to the patient.
the patient. If the liquid oxygen saturation temperature is too high, the corresponding high saturation pressure causes inaccurate flow
oxygen flow to the patient, as well as increased NER, loss of product, damage to components, etc. In both instances of either too low
or too high saturation temperatures, the same effects will be seen in portable devices that are filled off of the reservoirs.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
16
VIII Unpacking and Setup
Transport
1. Inspect carton for shipping damage. Report any damage to
freight company before signing bill of lading.
Specifically designed roller bases are available for moving
CAIRE reservoirs short distances on smooth surfaces. Hand
trucks can also be utilized for transport as well. CAIRE reservoirs may be moved about or transported in a vehicle while full
without damage; however, they should not be dropped, placed on
their sides or handled roughly in order to prevent damage.
2. Check description on carton against your order.
3. Unpack unit, including all accessories and documentation.
4. Set aside packing materials in case unit must be returned to
the factory.
Setup
NOTE: It is never acceptable to tip the reservoir to one side to
“roll” the unit, even if the unit is empty.
Companion Reservoirs
Unpacking
1. Locate and record the reservoir serial number. Reinstall the
shroud.
2. Visually inspect the reservoir for damage from improper
handling. Note any dents in the container, cracks in the
shroud, missing or loose hardware, and bent quick disconnect valves.
3. Check the vent valve for smooth operation. If possible,
connect a portable unit to the reservoir to check for smooth
coupling, and to make sure the portable unit is in proper
alignment with the reservoir when mated and there is no interference with the shroud or or case of portable unit.
4. Check all labels for damage and wipe away any dust on unit
with a clean, dry, lint-free cloth.
5. Verify the fill connector release button and mechanism
move freely.
6. Verify that an appropriate vent wrench is available for filling
of reservoir.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
17
IX Operation
g. Fully open reservoir vent valve.
NOTE: The fill source should have the correct fitting (5/8” x 45°
male flare) to connect to transfer line.
h. Engage the transfer line to the fill connector on the reservoir
unit by aligning the fill connector on the transfer line directly
over the fill connector on the reservoir and press downward.
Keep downward pressure in the transfer line during the entire
fill process.
1. Fill Source Preparation
a. Ensure the source contains a sufficient amount of liquid oxygen to completely fill the reservoir (approximately 120% of
reservoir volume).
b. Ensure the liquid oxygen in the fill source is saturated at 2,43,4 bar (35-50 psig).
NOTE: Proper saturation is critical when filling a CAIRE reservoir. If the fill source is not properly saturated, the process of properly saturating the reservoir will be difficult. If the reservoir is not
properly saturated, the unit will not function correctly, resulting in
inaccurate flow rates, excessive boil off of liquid. This will cause
portable units which are filled off the reservoir to act in the same
manner. Please refer to Section VII SATURATION PRINCIPLES
to learn more about the importance of proper saturation.
2. Fill Procedure
a. Required Equipment:
o Fill source as outlined above
o Liquid oxygen transfer line
o Female transfer line adapter for top fill reservoirs
o Eye protection
o Pressure gauge
o Insulated gloves
b. Connect transfer line to fill source. Connect proper transfer
line adapter to transfer line.
c. Fully open liquid valve on fill source.
d. Purge transfer line for a minimum of 5 seconds ensuring gas
is safely piped away from operator:
i. While filling, throttle the vent valve with the vent valve wrench
as needed to maintain pressure on the internal pressure gauge at
approximately1,2 - 1,5 bar/18 - 22 psig.
NOTE: Non-TPED Companion reservoir are not equipped with
internal pressure gauges. In any statement regarding internal pressure, if the unit does not have an internal pressure gauge, an external pressure gauge must be used by attaching it (P/N B-701732-00
or equivalent) to the Humidifier Adaptor and turning the FCV to a
setting of 2.0LPM or higher.
Companion Reservoirs
Filling
j. When a steady spray of liquid spurts from vent outlet, close
the vent valve completely.
k. Disconnect the transfer line from the reservoir by depressing
the portable release button and lifting the fill adapter straight
up.
l. If an external pressure gauge is used, disconnect pressure
gauge from humidifier adaptor and tun the FCV back to the
off position.
CAUTION: Do not allow excessive venting of liquid oxygen
through the vent valve. Prolonged exposure may freeze the valve
in the open position. If the vent valve freezes open, allow the
valve to warm up until it opens and closes freely and repeat the
fill process.
m.Verify that all flow rates are within tolerance specification
and that the liquid level meter indicates full.
i. Connect transfer hose fill adapter to a securely mounted mating QDV.
-OR-
ii. If the transfer hose adapter is equipped with a male
QDV, push adapter poppet against an unpainted stainless
steel surface.
NOTE: Purge the transfer line any time fill source valve has been
closed.
e. Wipe reservoir and transfer line adaptor fill connectors with
lint free rag if moist.
f. Weigh unit as required by local and federal standards.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
18
IX Operation
NOTE: The liquid level indicating system is accurate only after
the vent valve is closed, and the oxygen has stabilized for approximately five minutes.
As noted in the Theory of Operation, the Companion reservoirs
are equipped mechanical liquid level meters. The meter measures
the level of LOX remaining in the cryogenic vessel and displays
it on an integral indicator that is viewed through the top cover.
The liquid contents are indicated by aligning the colored line on
the piston with the graduated markings on the cylinder.
Cleaning and Disinfection
To insure proper functioning and end-user safety, CAIRE reservoirs should be cleaned whenever dirt or grime is visually apparent. The unit should be disinfected if required by applicable local
regulations or the home healthcare distributor’s own decontamination schedule.
Preparation
Prior to cleaning or disinfection, the unit should be completely
purged of LOX. The technician should wear appropriate safety
gear when performing the following procedures.
Cleaning
1. Remove the shroud and top cover and clean the interior and
exterior using only water. Wipe dry with a towel. Use cotton
swabs in tight places. Use Scotch- Brite pad lightly with detergent to remove scuff marks on the shroud.
2. Clean the contents indicator using one of the approved cleaners in Table 7. Do not spray cleaners directly onto the contents indicator. Spray cleaners onto a cloth and apply them
using the cloth. Make sure to rinse the surface of the contents indicator thoroughly with water after cleaning and then
wipe it dry.
3. Clean the reservoir plumbing and lower shroud with water.
Dry with a towel and oil-free compressed gas.
NOTE: Make sure that the fill connector and vent valve shaft are
thoroughly dry before proceeding.
4. Remove the condensate bottle and thoroughly clean and dry
it. Verify that the drain hole on the condensation ring and the
drain tube are open and unobstructed.
5. Clean the stainless steel container with oil-free cleaner and
towel.
Table 7 shows the approved cleaning and disinfecting
solutions are acceptable for use with Companion reservoirs.
TABLE 7: Recommended Cleaning and Disinfectant Solutions
Cleaning
Disinfecting
Sporicidin Disinfectant Solution
Mild dish washing detergent/warm water solution
Sporicidin Disinfectant Solution
Household Bleach (1:10 dilution with water,
freshly made within 24 hours)
Companion Reservoirs
Liquid Level Measurement
NOTE: After performing the cleaning/disinfecting process, it is
suggested to perform the following inspections and testing.
Inspection
• Inspect the shroud and top cover for cracks, warpage, and discoloration.
• Verify that the warning labels are present and legible on the
shroud and top cover.
• Verify that the Portable release mechanism moves freely and
is not worn. Verify that the release button is secure on the
lever and is not cracked.
• Verify that the fill connector is not worn or damaged and that
the poppet is not broken.
• Verify that the vent valve shaft pin and valve stops are not
bent or broken.
• Verify that the contents gauge is reading empty.
• Verify that the aluminum tubing is not bent or kinked and that
a uniform air gap exists between each coil.
Testing
1. Perform Leak Test.
2. Perform Liquid Oxygen Functional Tests.
3. Perform Gaseous Oxygen Functional Tests.
End of Life
At the end of the unit’s service life, all reservoir units must be
returned to a recycling facility in compliance with the Waste
Electrical and Electronic Equipment Directive (WEEE), or other
applicable codes and regulations. Alternatively, CAIRE may be
contacted for disposal information.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
19
X Maintenance (Schedule A, Biennial)
Schedule A – Biennial
A.Introduction
Routine maintenance is a series of steps used to assure that
equipment is functioning properly.
1. If a unit fails a given test, one of two things may be done:
3. Check Efficiency of Unit:
a. Inspect unit for cold or sweaty condition and for excessive
venting from relief valve (some venting is normal).
b. If either condition is observed, conduct NER test (RP23).
4. Prepare for Use:
a. Empty contents (RP3).
b. Clean and/or disinfect outside of unit following instruction set forth in the Operation section.
Companion Reservoirs
There are two schedules for routine maintenance which the
home health care distributor may follow. These schedules allow
the distributor maximum flexibility while assuring that equipment is operating properly. The healthcare distributor may follow either Schedule A or Schedule B, or a combination of the
two schedules. Maintenance checklists are provided for each
schedule. See below.
a. Refer to Troubleshooting section of this manual.
-or-
b. Return the unit to CAIRE, Inc. for repair.
2. Schedule – Maximum of two years between routine maintenance testing. Unit should be tested whenever a problem is
suspected.
B.Procedure
Follow the steps in order listed. If the unit fails any step, refer to
Troubleshooting section of this manual.
1. Visual Inspection:
a. Remove any LOX prior to maintenance (RP3).
b. Look for damaged or missing parts.
c. Verify that the contents indicator reads empty.
2. Component Test:
a. Remove shroud (RP5).
b. Perform Leak Test (RP2)
c. Perform PRV test (RP11).
d. Perform SRV test (RP12).
e. Pressure Retention Test (RP14).
f. Replace shroud (RP5).
g. Liquid Contents/Level Indicator Test (RP6)
h. Flow Rate test (RP20).
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
20
X Maintenance (Schedule A, Biennial)
Step 10 Year Service Life
Year 2
1
LOX Purged From Reservoir (Repair Procedure RP3)
Performed or Verified By/Date
2
Inpection for Damaged/Missing Parts
Performed or Verified By/Date
3
Contents Indicator Reads Empty
Performed or Verified By/Date
4
Remove Shroud (Repair Procedure RP5)
Performed or Verified By/Date
5
Perform Liquid Leak Detector Test (Repair Procedure
RP2)
Performed or Verified By/Date
6
Perform PRV Test (Repair Procedure RP11)
Performed or Verified By/Date
Year 4
Year 6
Year 8
Year 10
PRV Crack Pressure
Companion Reservoirs
Schedule A (Biennial) Maintenance Checklist
PRV Reseat Pressure
7
Perform SRV Test (Repair Procedure RP12)
Performed or Verified By/Date
SRV Crack Pressure
SRV Reseat Pressure
8
Pressure Retention Test (Repair Procedure RP14)
Performed or Verified By/Date
Internal Pressure after 10 Minutes
Internal Pressure after 60 Minutes
9
Replace Shroud (Repair Procedure RP5)
Performed or Verified By/Date
10
Liquid Contents/Level Indicator Test (Repair Procedure
RP6)
Performed or Verified By/Date
Liquid Contents/Level Indicator Display With 9-11kg
(20-25 lbs) of LOX
11
Flow Rate Test (Repair Procedure RP20)
Performed or Verified By/Date
Flow Rate at:
OFF
Flow Rate at:
0.12
Flow Rate at:
0.25
Flow Rate at:
0.5
Flow Rate at:
0.75
Flow Rate at:
1.00
Flow Rate at:
1.50
Flow Rate at:
2.00
Flow Rate at:
2.50
Flow Rate at:
3.00
Flow Rate at:
3.50
Flow Rate at:
4.00
Flow Rate at:
5.00
Flow Rate at:
6.00
Flow Rate at:
8.00
Flow Rate at:
10.00
12
Inspect for Cold or Sweaty conditon/ Excessive Venting
from RV
Performed or Verified By/Date
13
Perform NER Test (Repair Procedure RP23)
Performed or Verified By/Date
NER Results
14
Empty Contents from Reservoir (Repair Procedure RP3)
Performed or Verified By/Date
15
Clean and/or Disenfect Outside of Unit
Performed or Verified By/Date
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
21
X Maintenance (Schedule B, Continuous)
e. Visible dirt or contaminants inside and outside of the
shroud, as well as inside and outside of the condensate bottle
A.Introduction
f. Presence of all required labels
Continuous maintenance is a set of tests and inspections done
periodically to ensure equipment is functioning properly. It can
be performed by drivers or other personnel while the equipment
is in service.
g. If LOX is still present in the unit, inspect for heavy frost
or condensation on the exterior of the unit, which would indicate poor vacuum
h. Vent valve functionality (all parts are present and the
valve functions as it should)
1. If a unit fails a given test, it should be taken out of service
and sent to the Repair Center/Department for further inspection.
2. Schedule – Checks should be made before and after the
driver fills a unit at a patient location.
B. Pre Fill Procedure
1. Visually inspect for:
Companion Reservoirs
Schedule B – Continuous Pre and Post Fill Inspection
C. Post Fill Procedure
1. Visually verify:
a. QDV poppet is closed and not leaking
b. Vent valve is not leaking
c. No heavy frost or condensation is present on the
exterior of the unit
a. Broken shrouds or shroud components
b. QDV deformation
d. Contents gauge reads the accurate amount
c. Contents gauge functionality
d. Cryogenic reservoir damage (dents, scratches)
e. Pressure gauge is reading accurate pressure (if applicable)
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
22
X Maintenance (Schedule B, Continuous)
Pre Fill Visual Inspection
1
Broken Shroud or Shroud Components
Verified By/Date
2
QDV Deformation
Verified By/Date
3
Liquid Contents/Level Indicator Functionality
Verified By/Date
4
Cryogenic Reservoir Damage (Dents,Dings)
Verified By/Date
5
Visible Dirt or Contamination Inside and/or Outside of the Upper
Shroud, as well as Inside and/or Outside of the Condensate Collector
Verified By/Date
6
Presence of All Required Labels
Verified By/Date
7
If LOX is present in Unit, Inspect for Heavy Frost or Condnesation on
the Exterior of the Unit, Which Would Indicate Poor Vacuum
Verified By/Date
8
Vent Valve Functionality Ensuring that All Parts are Present and the
Valve Functions as it Should
Verified By/Date
Companion Reservoirs
Schedule B (Continuous Pre and Post Fill Inspection) Maintenance Checklist
Post Fill Visual Inspection
1
QDV Poppet is Closed and Not Leaking
Verified By/Date
2
Vent Valve is Not Leaking
Verified By/Date
3
No Heavy Frost or Condensation is Present on the Exterior of the Unit
Verified By/Date
4
Liquid Level Contents/Indicator Reads the Accurate Amount
Verified By/Date
5
Pressure Gauge is Reading Accurate Pressure (IF APPLICABLE)
Verified By/Date
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
23
XI
1 Troubleshooting & Repair Procedures
A.
B.
C.
Introduction------------------------------------------------------------------------------------------ 24
Troubleshooting Charts----------------------------------------------------------------------------- 25
Repair Procedures
RP1 General---------------------------------------------------------------------------------- 30
RP2
Leak Test-------------------------------------------------------------------------------- 30
RP3
Emptying/Purging Reservoir RR---------------------------------------------------- 31
RP4
Condensation Collector RR---------------------------------------------------------- 31
RP5
Shroud Assembly RR----------------------------------------------------------------- 31
RP6
Liquid Contents/Level Indicator Test----------------------------------------------- 32
RP7
Liquid Contents/Level Indicator RR------------------------------------------------ 32
RP8
Purging Liquid Contents/Level Indicator RR-------------------------------------- 32
RP9
Internal Pressure Gauge Test (if Equipped)---------------------------------------- 33
RP10
Internal Pressure Gauge RR (if Equipped)----------------------------------------- 33
RP11
PRV Test-------------------------------------------------------------------------------- 33
RP12
SRV Test-------------------------------------------------------------------------------- 33
RP13
PRV, SRV, R/E Valve RR------------------------------------------------------------ 34
RP14
Pressure Retention Test--------------------------------------------------------------- 34
RP15
Warming Coil Assembly RR--------------------------------------------------------- 35
RP16
Vaporizer Coil Assembly RR (if Equipped)--------------------------------------- 35
RP17
Vent Valve RR------------------------------------------------------------------------- 35
RP18
Fill Connector Release Assembly RR----------------------------------------------- 36
RP19
QDV Assembly RR-------------------------------------------------------------------- 36
RP20
Flow Rate Test------------------------------------------------------------------------- 37
RP21
Operating Pressure Test--------------------------------------------------------------- 37
RP22
Economizer Test----------------------------------------------------------------------- 37
RP23
NER Test-------------------------------------------------------------------------------- 38
RP24
FCV RR--------------------------------------------------------------------------------- 38
Companion Reservoirs
Table of Contents
Introduction
1. These procedures are designed to be performed only by qualified personnel with proper equipment.
2. Any failure during routine maintenance checks will refer you to this section. See troubleshooting chart for appropriate
procedure.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
24
XI
1 Troubleshooting & Repair Procedures
When more than one probable cause is identified, the causes are listed in order of most likely to least likely reasons for the problem.
Table 8
Symptom
1. Unable to start fill or
excessively long fill
times
Probable Cause
Corrective Action
a. Transfer line not engaged fully on Reservoir
QDV
a. Make sure the QDV on the transfer line and reservoir are properly aligned and ensure that a downward force is being applied to the transfer line
assembly.
b. Verify that pressure from the source is within the
35-50 psi range to fill the reservoir.
c. Ensure that the vent valve is able to be turned to the
fully open position.
d. Allow LOX to saturate to proper pressure.
e. Check fill connector and cartridge assembly for
damage; make sure fill connectors fully engage.
f. Inspect the valve for blockages and verify that flow
passes through during a fill. Clean by blowing out
with compressed gas or replace parts if necessary.
g. Check the reservoir for leaks (RP2) and repair if
needed.
a. Replace the QDV lip seal on the portable unit or
transfill adaptor.
b. Low source pressure
c. Vent valve not open or is blocked
d. Source tank is either under or oversaturated
e. Fill connector not opening properly
f. Vent valve is obstructed
g. Leak in the system
2. Liquid leaks from the
coupled QDVs during
the fill
a. Worn or damaged lip seal
3. Unable to disconnect
the transfer line or
portable unit from the
reservoir after a fill
a. Pop-off assembly not being utilized
4. Liquid leaks from the
QDV poppet after
filling
a. Ice crystal preventing the QDV from closing
properly.
5. Excessive venting from
relief valves (hissing
sound)
b. QDVs are frozen together
b. Dirty or damaged QDV poppet
a. Saturation pressure too high.
b. Relief valve frozen open
c. Faulty relief valve
d. Partial or complete loss of vacuum
Companion Reservoirs
Table 5 below provides troubleshooting procedures for the Companion reservoir. This guide is not all-inclusive but is intended to
serve as a general outline for solving operational problems. The table describes symptoms, identifies probable causes, and suggests
corrective actions.
a. Ensure that the pop-off assembly on the reservoir
is being used. Do not use force to separate the
QDVs.
b. Leave the units coupled with the vent valve closed
and let them sit until they warm up enough to
disconnect. Always ensure that male and female
QDV’s are cleaned and dried prior to each fill.
a. Engage and disengage the transfer line onto the
reservoir several times to dislodge the ice crystal.
Always be sure that the male and female QDVs are
wiped clean and dry before filling.
b. Replace the QDV assembly (RP19)
a. Inspect the saturation pressure of the reservoir used
for filling. Allow at least 30 minutes at no flow for
the portable to saturate properly.
b. Allow the portable to warm and thaw. Attempt to
re-fill the portable.
c. Test the relief valves (RP11/RP12) and replace if
necessary (RP13)
d. Conduct the NER test (RP23) and return the unit to
CAIRE, inc. if necessary.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
25
XI Troubleshooting & Repair Procedures
Symptom
6. No flow at oxygen outlet
Probable Cause
a. Reservoir is empty
b. Flow control valve turned off
c. Nasal cannula kinked or disconnected
d. Saturation pressure is too low
e. Leak in the system
f. Relief valve is open
g. Vent valve is open
h. Blockage in the liquid withdrawal circuit
7. Low flow at oxygen outlet
on all LPM settings
i. FCV Faulty
a. Nasal cannula kinked or leaking
b. Saturation pressure is too low
c. Leak in the system
d. Economizer valve faulty
e. Blockage in the liquid withdrawal circuit
or the flow restrictor
8. Increased NER
f. FCV faulty
a. Saturation Pressure is too high
b. Leak in the system
c. Relief valve open
d. Partial or complete loss of vacuum
Corrective Action
a. Check the contents indicator/level gauge and fill
the reservoir if needed.
b. Ensure the flow control knob is not in the off (“0”)
position.
c. Ensure proper nasal cannula functionality and positioning
d. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
e. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
f. Ensure that there is no venting from the relief
valves. If there is refer to the corrective actions
for “Excessive venting from relief valves (hissing
sound)”
g. Ensure that the vent valve is fully closed and not
leaking.
h. Check the warming coils and withdrawal tubes for
blockages. Replace if necessary.
i. Replace the FCV (RP24)
a. Inspect the functionality of the nasal cannula.
b. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
c. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
d. Test the economizer (RP22) and replace (RP13) if
necessary.
e. Check the warming coils and withdrawal tubes as
well as the flow restrictor for blockages. Replace
if necessary.
f. Replace the FCV (RP24)
a. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
b. Perform a leak check on the plumbing (RP2) and
a pressure retention test (RP14). Repair leaks as
necessary.
c. Ensure that there is no venting from the relief
valves. If there is refer to the corrective actions
for “Excessive venting from relief valves (hissing
sound)”
d. Conduct the NER test (RP23) and return the unit
to CAIRE, inc. if necessary.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
Companion Reservoirs
Table 8 (cont.)
26
XI Troubleshooting & Repair Procedures
Symptom
Probable Cause
a. Frost is acceptable
9. Excessive Frost
NOTE: Minimal frost on
the shroud and on the
plubming is normal. This
symptom applies to frost
b. High humidity level
that is much greater than
what is normally observed.
c. Saturation pressure is too high
d. Leak in the system
e. Relief valve open
f. Partial or complete loss of vacuum
10. Unit will not maintain acceptable system pressure
a. Saturation pressure is unacceptable
b. Vent valve not completely closed
c. Leak in the system
d. Economizer valve faulty
e. Primary releif valve faulty
11. High Pressure at Reservoir a. Saturation pressure is too high
oxygen outlet
b. Primary releif valve set too high or relief
valve operating improperly
c. Economizer valve stuck in closed state
d. Partial or complete loss of vacuum
12. Contents indicator reads
incorrectly
Corrective Action
a. Some frost on the shroud and on the plumbing is
acceptable, especially at high flow rates during
continuous use. This is due to the evaporation of
LOX to gas and the temperature difference between the LOX and room temperature.
b. High humidity levels can increase frost accumulation.
c. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
d. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
e. Ensure that there is no venting from the relief
valves. If there is refer to the corrective actions
for “Excessive venting from relief valves (hissing
sound)”
f. Conduct the NER test (RP23) and return the unit
to CAIRE, inc. if necessary.
a. Inspect the saturation pressure of the reservoir
used for filling. Allow at least 30 minutes at no
flow for the portable to saturate properly.
b. Close vent valve. Leak check vent valve outlet and
stem. Replace or repair as needed.
c. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
d. Test the economizer (RP22) and replace (RP13) if
necessary.
e. Test the primary relief valve (RP11) and replace
(RP13) if necessary
a. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
b. Perform relief valve test (RP11). Replace (RP13) as
needed.
c. Perform Economizer test (RP22). Replace (RP13)
as needed.
d. Conduct the NER test (RP23) and return the unit
to CAIRE, inc. if necessary.
a. Perform leak test (RP2). Repair leaks as needed.
Companion Reservoirs
Table 8 (cont.)
a. Leak in the sensing tubes,fittings, or the
Contents Indicator.
b. Flexible contents indicator pressure sens- b. Visually inspect the flexible pressure sense tubes
ing tube pinched.
and remove pinching conditions.
c. Ice blockage in contents indicator (liquid) c. Perform the Purging Liquid Contents/Level
pressure sense tube.
Indicator (RP8) procedure.
d. Contents indcator damaged
d. Replace contents indicator (RP7) as needed.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
27
XI Troubleshooting & Repair Procedures
Companion Reservoirs
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
28
XI Troubleshooting & Repair Procedures
Companion Reservoirs
To use the Troubleshooting Chart:
• Start at the upper left corner.
• The top line shows the steps of routine maintenance.
• Unless otherwise noted by the arrows, the flow through the chart is down or to the right.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
29
XI Troubleshooting & Repair Procedures
The following procedures have been carefully prepared to allow
proper removal and replacement of defective components and
should be used in conjunction with the Troubleshooting Chart and
the tests in this section.
CAUTION: When replacing components, make sure the new
part is oriented exactly the same as the original part prior to
installation.
CAUTION: Some components require a specific amount of
torque when assembling. Follow torque requirements where
specified.
NOTE: All replacement parts must be factory approved, cleaned
for oxygen service, and stored in sealed plastic bags. The repair
area must be clean and separate from other areas. Room air should
be filtered, and free from dust, soot, and other contaminants.
NOTE: When replacing components with pipe threads, use PTFE
tape thread sealant. Apply two rounds of PTFE tape to threads
near end of component, avoiding first thread.
NOTE: When assembling new compression fittings, tighten 1/8”,
1/4” and 1/2” nuts eight flats past finger tight and 3/16” nuts five
flats past finger tight. When reassembling previously used compression fittings, tighten nuts one to two flats past finger tight.
RP2 – Leak Test
1. Attach the pressurizing fixture (PN B-701731-SV) to the
fill connector on the reservoir unit and secure it with the attached strap.
2. If the reservoir contains liquid oxygen, verify that it is pressurized between 1.4 to 1.7 bar/21-25 psi.
3. If the reservoir does not contain liquid oxygen, connect an
adjustable 0 to 6,9 bar/0 to 100 psig source of gaseous oxygen to the DISS oxygen inlet on the pressurizing fixture.
Companion Reservoirs
RP1 – General
4. Pressurize the reservoir with gaseous oxygen to between 1.4
to 1.7 bar/21-25 psi.
5. Use SNOOP to test all reservoir fittings and connections.
NOTE: When using SNOOP on the stem of the vent valve, be
sure to blow it dry with gaseous oxygen or nitrogen before and
after test.
6. Place a finger wetted with Snoop lightly against the vent
valve outlet to test for leakage.
7. Disconnect and remove the pressurizing fixture from the reservoir fill connector.
8. Apply SNOOP to the fill connector poppet and check for
leakage.
9. Use dry Nitrogen or Oxygen gas to dry SNOOP off poppet.
10. Make repairs to leaking fittings or connections as needed
and perform leak check on those fittings again.
NOTE: A small amount of leakage around the poppet of the male
fill connector is acceptable. Acceptable leaks appear as white,
foam-like bubbles in the liquid leak detector. If the bubbles created by the leak detector are considerably large, make necessary
repairs to the male fill connector.
11.Make repairs to leaking fittings or connections as needed
and perform leak check on those fittings again.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
30
XI Troubleshooting & Repair Procedures
NOTE: Ensure that the area in which the following procedure will
be performed is properly ventilated and free of ignition sources.
NOTE: Ensure vent valve on reservoir is placed in a manner so
as not to vent in the direction of technician or individuals nearby
or walking by.
1. Connect an adjustable 0-6,9 bar/0-100 psig pressure regulator to oxygen or nitrogen gas source.
RP4 – Condensation Collector RR
1. Remove condensate drain tube from bottle and remove bottle from bracket.
2. Remove condensate bottle bracket squeezing legs together
and pulling straight down.
3. To replace bracket and bottle, reverse above procedure.
RP5 – Shroud Assembly RR
2. Attach the pressurizing fixture (PN. B-701731-SV) to the
fill connector on the reservoir unit and secure it with the attached strap.
1. Unscrew the screw in the top center of the top cover.
3. Connect the pressurizing fixture to the regulator on the gas
source using a pneumatic hose or similar tubing.
3. To remove the cover body from the top cover, unscrew the
five small pan head screws on the underneath side of the top
cover.
4. Open the main valve on the gas source.
5. Open vent valve on reservoir to allow slow venting.
NOTE: If the reservoir is near full of LOX, some LOX may momentarily spray from vent valve.
6. Adjust regulator to a pressure setting that is slightly higher
than the internal pressure of the unit (Example: If the internal pressure gauge or gauge on the pressurizing fixture
reads 1,5 bar/22 psig, adjust the regulator attached to the gas
source to approximately 1,7-1,8 bar/24-26 psig).
Companion Reservoirs
RP3 – Emptying/Purging Reservoir
2. Carefully lift up to remove the entire shroud assembly.
NOTE: New labels must be installed any time the shroud is replaced. Make sure that the front warning label is the correct one
for the model of reservoir it is to be used on.
NOTE: Be sure to align the shroud so that the access holes are
positioned directly over the corresponding reservoir plumbing
components. Also, be sure that the shroud is seated uniformly on
the lower shroud lip.
4. To replace the cover body, reverse the above procedure.
7. Allow unit to purge until the exhaust that is released out of
the vent valve is clear and the internal components are free
of frost. (Approximately 45 minutes)
NOTE: This process can be time consuming depending on the
level of LOX in the unit. The pressurizing fixture can be secured
to the reservoir using straps, bungee cord, etc., as long as the vent
valve is open.
8. Remove pressurizing fixture from reservoir.
9. Close main valve on gas source.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
31
XI Troubleshooting & Repair Procedures
1. Verity that when the tank is empty the colored line on the
contents indicator is aligned with the “0” marking.
2. Fill the reservoir so it contains 9 to 11 kg/ 20 to 25 lbs. of
liquid oxygen.
2. Verify that within five minutes, the center of the colored
line on the contents indicator piston is within the proper
range indicated by the shaded bar in Figure 11.
RP8 – Purging Liquid Contents/Level Indicator RR
1. Ensure reservoir is empty, warm and free of internal pressure per RP3.
2. Remove the shroud per RP5.
3. Use the vent wrench to open the vent valve on the reservoir
unit.
4. Connect a pressurizing fixture (B-701731-SV or similar) to
the fill connector on the reservoir unit and secure it with the
attached strap.
Companion Reservoirs
RP6 – Liquid Contents/Level Indicator Test
5. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the DISS oxygen inlet on the pressurizing fixture.
Companion 41
6. Adjust the regulator on the gaseous source until the gauge
on the pressurizing fixture reads approximately 1,0 bar/15
psig.
7. With only the vent valve open, allow the system to purge for
about 45 minutes.
Figure 13
RP7 – Liquid Contents/Level Indicator RR
CAUTION: Damage to contents/level indicator or barbed fittings
can occur. Vent reservoir pressure before removing either contents indicator tube. Use care when removing flexible tubes from
barbed fittings or contents/level indicator
1. Remove shroud per RP5.
2. Remove the flexible pressure sensing lines from the barbed
fittings on the contents gauge by carefully sliding the brass
collar away from the barbed fitting and then disconnecting
the sensor line.
3. Use a medium flat blade screwdriver to remove the two
screws that fasten the contents gauge to the mounting plate.
4. To replace the contents gauge, reverse the above procedures.
8. Disconnect the pressurizing fixture.
9. With no pressure in the unit, disconnect both pressure
sensing tubes from the contents indicator. Using a wire tie,
lightly secure the tubes to the vent valve to prevent them
from moving around.
CAUTION: Damage to the contents indicator can occur.
Disconnect both contents indicator tubes before pressurizing the
reservoir. Vent the reservoir before connecting or disconnecting
indicator tubes.
10.Close the vent valve. Reconnect the pressurizing fixture and
adjust the regulator until the pressurizing fixture reads approximately 1,0 bar/15 psig.
11.Allow an additional 15 minutes for gas to flow through and
purge the contents indicator tubes.
12.Disconnect the pressurizing fixture and open the reservoir
vent valve.
13.Reconnect both pressure sense tubes to the contents indicator.
14.Perform the contents indicator test (RP6).
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
32
XI Troubleshooting & Repair Procedures
1. Engage the pressurizing fixture to the fill connector on the
reservoir and secure it with the attached strap.
2. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the Diameter Index Safety System (DISS) oxygen
inlet on the pressurizing fixture.
3. Slowly pressurize the reservoir until the needle of the reservoir pressure gauge lines up with the 20 psig mark.
4. Verify that the reading on the pressurizing fixture gauge is
within the blue acceptable region.
NOTE: It may be necessary to tap on top of the indicator with
your finger to assure that the indicator is operating properly.
8. If either the opening pressure or closing pressure readings of
the PRV do not meet the specifications stated in previous
steps, replace the R/E valve.
9. Disconnect the pressurizing fixture and open the reservoir
vent valve to reduce the pressure below 1,4 bar/20 psig.
RP12 – SRV Test
1. Remove shroud per RP5.
2. Engage the pressurizing fixture to the fill connector on the
reservoir and secure it with the attached strap.
Companion Reservoirs
RP9 – Internal Pressure Gauge Test (If Equipped)
3. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the DISS oxygen inlet on the pressurizing fixture.
4. Obtain a type of temporary clamp.
RP10 – Internal Pressure Gauge RR (If Equipped)
1. Remove the shroud and top cover per RP5.
2. Use a 5/8 in. or 3/4 in. open end wrench to hold the brass
fitting below the pressure gauge which is attached to the
gauge.
NOTE: If the R/E valve contains a muffler or any other type of
exhaust fitting, remove fitting prior to installing clamp.
5. Position the movable bar clamp arm over the R/E valve vent
and position the fixed bar clamp arm.
6. Tighten the clamp to seal the vent port.
3. Use a 1/2 in. or 9/16 in. open end wrench to loosen the pressure gauge from the brass fitting until the gauge is free.
7. Slowly pressurize the reservoir by adjusting the oxygen
source regulator.
4. Reverse the procedures above to reinstall the internal pressure gauge.
8. Verify that the secondary relief valve opens (audible hiss) at
2,1 bar/30 psig +/- 5%.
RP11 – PRV Test
1. Remove the shroud per RP5.
NOTE: If the secondary relief valve does not open within this
range the first time, first increase the pressure to ensure the SRV
has cracked, then reduce the pressure in the reservoir and repeat
the test a second time. If it fails to open within the acceptable
range the second time, replace the valve SRV.
NOTE: If the R/E valve contains a muffler or any other type of
exhaust fitting, remove fitting prior to testing.
9. Slowly reduce the pressure within the reservoir until the audible hissing noise is no longer heard.
2. Engage the pressurizing fixture to the fill connector on the
reservoir and secure it with the attached strap.
10. Verify that the SRV closes (audible hiss is no longer heard)
at a pressure greater than 1,9 bar/27 psig.
3. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the DISS oxygen inlet on the pressurizing fixture.
4. Slowly pressurize the reservoir until a “hiss” is heard coming from the PRV.
NOTE: If the secondary relief valve does not close within this
range the first time, repeat the SRV testing. If it fails to open
within the acceptable range the second time, replace the SRV
valve. ­
5. Verify that the PRV opens (hissing) at less than 1,7 bar/25
psig
11.Disconnect the pressurizing fixture and open the reservoir
vent valve to reduce the pressure below 1,4 bar/20 psig.
­6. Slowly reduce the pressure within the reservoir until the
hissing through the PRV stops.
12. Remove the clamp blocking the R/E valve vent port.
7. Verify that the PRV closes (hissing stops) at a pressure
greater than 1,4 bar/21 psig.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
33
XI Troubleshooting & Repair Procedures
1. Remove the shroud per RP5.
2. Use a 5/8-in. open-end wrench to remove the SRV from the
PRV, R/E valve.
RP14 – Pressure Retention Test
WARNING: Reservoir must be empty and vented before starting procedure.
1. Attach pressurizing fixture to the QDV on the reservoir.
3. Slide the press-on tubing clamp back and disconnect the
flexible (gas) pressure sense tube from the 1/16-in. barbed
fitting on the PRV, R/E valve.
2. Connect an adjustable 0-6,9 bar/0-100 psig source of gaseous oxygen to the DISS oxygen inlet on the pressurizing
fixture.
4. Use a 1/4-in. open-end wrench to remove the 1/16-in. barbed
fitting.
3. Pressurize the unit to 1,5 bar/22 psig.
5. Use a ½ -in. open-end wrench to remove the economizer
tube assembly inverted compression nut from the PRV, R/E
valve.
NOTE: Lightly tap the pressure gauge with your finger to assure
that the needle is reading properly.
4. Remove the pressurizing fixture.
6. Carefully pull the economizer tube down until it clears the
PRV, R/E valve.
5. Let the unit stand for 10 minutes to allow the pressure inside
the reservoir to stabilize.
7. Use a ¾ -in. open-end wrench to remove the PRV, R/E
valve from the threaded manifold extension tube.
6. Engage te pressurizing fixture (without the gaseous oxygen
source) to the QDV on the reservoir.
8. Apply Teflon tape sealant to the threaded manifold tube facing the embossed circular index mark on the top of the lower
shroud.
7. Verify internal pressure is approximately 1,4–1,7 bar/20.5–
25 psig.
9. Install the PRV, R/E valve on the threaded manifold tube
and tighten so that the SRV port is in a vertical, up position.
10.Install the end of the economizer tube with the inverted
compression nut in the bottom port of the PRV, R/E valve.
8. Record the initial time and pressure.
NOTE: Lightly tap the pressure gauge with your finger to assure
that the needle is reading properly.
9. Allow unit to sit undisturbed for 60 minutes.
11.Make sure the tube end is aligned properly in the port and
then tighten the inverted compression nut.
10.Engage the pressurizing fixture (without the gaseous oxygen
source) and take a final reading.
12.Install the 1/16-in. barbed fitting in the PRV, R/E valve port
that faces the center of the reservoir.
11.Verify that the pressure is greater than1 bar/15 psig.
13.Connect the flexible tube and the tubing clamp to the barbed
fitting.
14.Apply Teflon tape sealant to the SRV threads.
Companion Reservoirs
RP13 – PRV, SRV, R/E Valve RR
NOTE: If the pressure is out of specification, perform the leak
Detector Test to determine the source of the leak.
12.Disconnect the pressurizing fixture.
15.Install the secondary relief valve in the PRV, R/E valve port
and tighten until snug.
16.Perform leak test.
17.Install the shroud.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
34
XI Troubleshooting & Repair Procedures
TPED Models manufactured prior to June 2011
3. Use a 9/16 in. open end wrench to remove the compression
nut from the tee that connects to the manifold while holding
the tee stationary with an adjustable wrench.
1. Remove shroud per RP5.
4. Remove the coil.
2. Remove three screws from mounting brackets that
attach warming coil to the condensation ring using
a Phillips head screwdriver.
5. To reinstall or replace the warming coil, reverse the above
procedure.
3. Slightly lift warming coil up from condensate ring to
allow access to tee fitting on top of outer shell.
4. Use a 9/16 in. open end wrench to remove the compression
nut from the tee fitting while holding the tee fitting stationary with an adjustable wrench.
5. Use a 9/16-in. open-end wrench to remove the warming coil
compression nut from the tee fitting on the FCV.
6. Pull the aluminum warming coil tube away from the tee and
carefully guide the small Teflon liquid withdrawal tube out
of the aluminum tube.
11.To reinstall or replace the warming coil, reverse the above
procedure.
All domestic units and TPED units manufactured after June
2011
1. Remove shroud per RP5.
2. Use a 9/16 in. open end wrench to remove the compression
nut from the tee fitting while holding the tee fitting stationary with an adjustable wrench.
3. Use a second 9/16-in. open-end wrench to remove the
warming coil compression nut from the bottom of the FCV.
4. Pull the aluminum warming coil tube away from the tee and
carefully guide the small Teflon liquid withdrawal tube out
of the aluminum tube.
5. To reinstall or replace the warming coil, reverse the above
procedure.
RP17 – Vent Valve RR
Companion Reservoirs
RP15 – Warming Coil Assembly RR
1. Remove shroud per RP5.
2. Use a 3/4-in. open-end wrench to remove the vent valve.
Place the wrench on the valve hex flats closest to the manifold to prevent disassembly of the valve as you remove it.
3. Inspect the valve stem O-ring and spring pin for wear or
damage.
4. Inspect the vent wrench stops on the valve body for wear or
damage.
5. Use a 3/4-in. open-end wrench to hold the outer hex flats
of the vent valve stationary while using a 9/16-in. open-end
wrench to remove the vent extension.
6. Lightly clamp the vent valve in a vise.
7. Use a pin punch and a hammer to drive the spring pin out of
the valve stem.
8. Use a small screwdriver to carefully pry the retainer ring off
of the valve stem.
9. Use a dental pick or similar object to lift the O-ring off the
valve stem.
10.To reinstall or replace the vent valve, reverse the above procedure.
NOTE: Before installing the vent valve, wrap the threaded manifold extension tube with Teflon tape starting two threads back
from the end. Verify that the arrow on the vent valve body points
away from the manifold.
RP16 – Vaporizer Coil Assembly RR (if equipped)
1. Remove shroud per RP5.
2. Use a 9/16 in. open end wrench to remove the compression
nut from the dropout tee while holding the dropout tee stationary with an adjustable wrench.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
35
XI Troubleshooting & Repair Procedures
Companion Reservoirs
RP18 – Fill Connector Release Assembly RR
1. Remove shroud per RP5.
2. Use needle nose pliers to remove one E-clip from the release
lever pivot pin.
3. Remove the pin from the release lever.
4. Remove the lever from the mounting bracket.
5. Use a No. T10 Torx driver to remove two Torx screws from
the release button.
6. Remove the button from the lever.
7. To reinstall or replace the fill connector release assembly,
reverse the above procedure.
RP19 – QDV Assembly RR
1. Remove shroud per RP5.
2. Remove the fill connector release assembly.
3. Use a 7/8-in. open-end wrench to hold the body of the fill
connector stationary.
4. Use a 10-in. adjustable wrench to loosen the compression
nut on the fill connector.
5. Remove the fill connector.
6. To reinstall or replace the QDV, reverse the above procedure.
7. Ensure to add a small amount of Krytox lubricant on the
threads of the QDV.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
36
XI Troubleshooting & Repair Procedures
RP21 – Operating Pressure Test
1. Ensure unit is at least ½ to ¼ full of LOX.
2. If LOX is added to reservoir, allow unit to sit for a minimum
of 1.5 hours prior to beginning test.
3. Attach a DISS fitting adapter (PN B-775269-00) to the humidifier adapter which is attached to the FCV.
4. Connect flow meter inlet to the DISS fitting adapter (PN
B-775269-00) using respiratory tubing.
5. Make sure flow meter outlet is open and unobstructed and
flow meter is properly positioned.
6. Test flow rate at each FCV position.
7. Compare flow rates to the table below.
NOTE: Be careful to allow for accuracy tolerances of flow meter.
Table 6 below does not account for these tolerances.
Table 9
FCV Setting
OFF
0.12
0.25
0.50
0.75
1.00
1.50
2.00
2.50
3.00
3.50
4.00
5.00
6.00
8.00
10.0
LPM
0
0.02-0.22
0.08 to 0.42
0.33 to 0.67
0.58 to 0.92
0.83 to 1.17
1.18 to 1.82
1.61 to 2.43
2.08 to 2.97
2.55 to 3.51
2.92 to 4.04
3.43 to 4.62
4.33 to 5.77
5.14 to 6.92
6.72 to 9.28
8.42 to 11.53
NOTE: If testing operating pressure because of improper flow
rates, test pressure immediately after flow rate test.
1. Ensure unit contains at least 9 kg/20 lbs. of LOX.
2. If LOX is added to reservoir, allow unit to sit for a minimum
of 1.5 hours prior to beginning test.
3. Attach a DISS fitting adapter (PN B-775269-00) to the humidifier adapter which is attached to the FCV.
Companion Reservoirs
RP20 – Flow Rate Test
4. Attach a 0-6,9 bar/0-100 psig pressure gauge to the DISS fitting adapter (PN B-775269-00).
5. Open the FCV to any setting above 2 LPM.
6. Pressure gauge should read between 1,2-1,4 bar/18.5-20.5
psig.
RP22 – Economizer Test
1. Verify that the reservoir contains at least 9 kg/20 lbs of
LOX.
2. If LOX is added to reservoir, allow unit to sit for a minimum
of 1.5 hours prior to beginning test.
3. Engage the pressurizing fixture (PN B-701067-SV) to the
fill connector on the reservoir and secure it with the attached
strap.
4. Adjust FCV knob to a setting of 4 LPM.
5. With the unit delivering an oxygen flow, record the pressure
readings on the pressurizing fixture gauge every half hour
until the pressure stabilizes.
6. Stabilization occurs when two consecutive readings are
within .01 bar/.2 psig of each other.
7. If the readings do not stabilize, replace the economizer
valve.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
37
XI Troubleshooting & Repair Procedures
1. Fill the unit with 9 to 11 kg/20 to 25 lbs. of properly saturated liquid oxygen.
On units without an Internal Pressure Gauge:
2. Allow unit to sit undisturbed for a minimum of 12 hours.
1. Use a 1/2-in. open-end wrench to remove the humidifier
adapter.
3. Weigh unit.
2. Remove the shroud per RP5.
4. Record weight and time (1st Recorded Weight).
3. Use a 1/2-in. open-end wrench to hold the elbow fitting and
use a 9/16-in. open-end wrench to remove the breathing coil
nut from the elbow.
5. Allow unit to sit undisturbed for a minimum of 24 hours.
6. Weigh unit.
7. Record weight and time (2nd Recorded Weight).
4. Use a 1/2-in. open-end wrench to remove the elbow fitting
from the bottom of the FCV.
8. Calculate liquid loss rate (NER) using the following formula:
5. Use a Phillips head jeweler’s screwdriver to remove the two
Phillips head screws on the bottom of the mounting bracket
which secure the FCV to the bracket.
1st Recorded Weight - 2nd Recorded Weight
6. Replace FCV.
Elapsed Time Between Weights in hrs
X 24 Hours
Companion Reservoirs
RP24 – FCV RR
RP23 – NER Test
7. To reinstall the FCV, simply reverse the instructions above.
On units with Internal Pressure Gauges
9. The NER should be between .73 - 1.0 kg/1.6 - 2.2 lbs per
day.
1. Use a 1/2-in. open-end wrench to remove the humidifier
adapter.
2. Remove the shroud per RP5.
3. Use a 1/2-in. open-end wrench to hold the tee fitting and use
a 9/16-in. open-end wrench to remove the breathing coil nut.
4. Use a 1/2-in. open-end wrench to hold the tee fitting and use
a 9/16-in. open-end wrench to remove the pressure gauge
tube nut.
5. Use a 1/2-in. open-end wrench to hold the tee fitting and use
a 9/16-in. open-end wrench to remove the tee adapter going
into the bottom of the FCV.
6. Use a Phillips head jeweler’s screwdriver to remove the two
Phillips head screws on the bottom of the mounting bracket
which secure the FCV to the bracket.
7. Replace FCV.
8. To reinstall the FCV, simply reverse the instructions above.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
38
XII
1 Parts List
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
Companion Reservoirs
Contact Customer Service or visit www.cairemedical.com
to obtain your parts list.
39
XIII Ordering Information
The following steps should be used when ordering a new
Companion or replacement parts for an existing unit:
1. Compile a list of all equipment and replacement parts to be
ordered.
2. Fill out a purchase order containing the following information:
a. Purchase order number.
b. Name and address of billing location.
c. Name and address of shipping location.
d. Quantity, part number, description, and unit cost
for each item ordered.
3. Telephone or fax CAIRE Inc. at one of the numbers listed
below to begin immediate processing of the order:
USA
Toll Free Phone:
800 48 CAIRE
(800 482 2473)
Toll Free Fax: 888 WE CAIRE
(To place an order):(888 932 2473)
Phone:
770 721 7759
Fax: 770 721 7758
4. E-Mail or fax the completed purchase order for confirmation to:
North and South America/Asia/Pac Rim email to:
[email protected]
Africa/Europe/Middle East email to:
[email protected]
North and South America fax to: 888-932-2473
Asia/Pac Rim fax to: 770-721-7758
Companion Reservoirs
Ordering Information
Africa/Europe/Middle East fax to: +44 118 9799245
All new equipment will be shipped either “prepaid”,, F.O.B. from
the factory, or collect via your specified carrier. All replacement
parts will be sent by UPS “prepaid”, and the shipping charges for
equipment and parts will be added to the final invoice. Payment for
replacement parts are located on CAIRE, Inc.’s, invoice with payment date indicated. All shipments will originate from the factory. If
a particular carrier or method of shipment is desired, specify when
placing order.
Asia, Australia, Pacific Rim
Phone:
+61 297 494333
Fax:
888 932 2473
Europe
Phone:
Fax:
+44(0) 1189 367080
+44 118 9799245
For additional ordering and contact
information, visit www.cairemedical.com.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
40
XIV Return & Restocking Policy
If a problem with the unit should be encountered, reference
should be made to the Troubleshooting Chart. If these procedures
do not provide a solution for the problem, the following steps
should be taken:
1. Call CAIRE, Inc. Customer Service.
North and South America/Asia/Pac Rim:
Phone (US Only)
800-482-2473
Phone
770-721-7759
Phone
If it becomes necessary to cancel an order with CAIRE Inc. after the shipment has been received, use the following “Restock
Policy” procedure:
1. Call CAIRE, Inc. Customer Service.
2. When contacting Customer Service personnel, it will be necessary to relay the following information:
a. State the quantity and description of equipment to be returned.
b. Give the Serial Number of each unit to be returned.
c. State the equipment purchase date.
Africa/Europe/Middle East:
Restocking Policy
Companion Reservoirs
When a CAIRE unit is received, it should be inspected immediately, as outlined in Section VII, Unpacking and Setup
Instructions.
+44 (0) 1189 367080
2. State the problem with the unit.
3. If it is determined that the problem cannot be solved by the
distributor, a Return Material Authorization (RMA) number
will be assigned to the unit or part(s).
4. If a Purchase Order Number is to be referenced, please give
this number to the Customer Service Representative at that
time.
5. Carefully package the parts, or repack the unit in its original
shipping container, precisely as shipped.
6. Write the Return Authorization Number on the top of the
shipping container.
7. Customer Service will provide the correct shipping location
once the RMA is provided
3. An RMA number will be issued in the name of the distributor by CAIRE, Inc. for the equipment to be returned.
4. When the equipment is shipped to the factory, the RMA
number must appear on the packing slip and shipping boxes.
5. Customer Service will provide the correct shipping location
once the RMA is provided
6. Finally, a “Credit Memo”, minus a 15% restocking fee, will
be issued to the distributor when all equipment has been received, inspected, and restocked by CAIRE, Inc
Return of Unused Non-Defective Merchandise
CAIRE Inc., at its discretion, charges a 15% restocking fee for
unused non-defective merchandise that is returned. An RMA
number must be obtained from CAIRE Inc. Customer Service
prior to return of any goods. Merchandise cannot be returned for
credit after sixty (60) days. Customer to pay all freight charges.
Tracking capability and insurance on all returned goods is advised. CAIRE Inc. will not be responsible for misdirected shipments.
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
41
XV Service Tools/Equipment/Supplies
Table 12
Required Tools
Required Supplies
Hex Wrenches (various sizes)
Household Glass Cleaner
Phillips Blade Screwdriver
PTFE Tape
Torx T 10 Screwdriver
Leak Detection Fluid
Flat Blade Screwdriver
Lint-Free Cloth
10 in. Adjustable Wrench
Fluorolubricant
Open End Wrenches (1/2” to 1-1/8”)
Isopropyl Alcohol
Side Cutters
Companion Reservoirs
Table 10
Pliers
Clamp or Hemostat
6 in. Bar Clamp
Dental Pick
Table 11
Required Fixtures/Equipment
Oxygen Regulator
Vent Valve Wrench
0-6,9 bar/0-100 psig Pressure Gauge
Pressurizing Fixture
Flowmeter
Gaseous Oxygen Source 0-6.89 bar (0-100 psi)
O2 Liquid Source
N2 Gas or Clean, Dry Compressed Air Source
Tubing (O2 compatible)
O2 Tubing Tee Connector
LO2 Transfer Line
Transfer Line Adapter with Filter
Dewar Cap
Scale 0-92 kg/0-200 lbs, 0.05 lb/0.02 kg increments
Size 00 Rubber Stopper
DISS O2 Outlet Connector
Small Tie Wrap/Zip Tie
Oxygen Supply Tube Coupler
For a complete list of accessories, see catalog ML120071 on www.cairemedical.com
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
42
XV Service Tools/Equipment/Supplies
Description­
Item Number
Description­
Item Number
Vent Wrench
B-775182-00
Transfer Line Assembly (10 ft./3 m)
B-775289-00
0-6,9 bar/0-100 psig Pressure Gauge
B-776004-00
0-4,1 bar/0-60 psig Pressure Gauge
97403577
• Transfer Hose (6 ft./1.8 m)
B-775280-00
Pneumatic Hose w/DISS Fittings
97405279
• Transfer Hose (10 ft./3 m)
B-775281-00
Small Tie Wrap
B-775091-00
• Source Adapter Assembly
B-775279-00
Tubing Barb Adaptor
B-775269-00
• Relief Valve (10,4 bar/150psi)
B-775273-00
Disposable Tubing Barb Adaptor
B-776945-00
• Source Adapter
B-775313-00
O2 Compatible Tubing
B-778214-00
• Fill Adapter Assembly
B-775278-00
Test Pressure Gauge w/Tubing Adapter
0-6,9 bar/0-100 psig
• Fill Adapter
B-775312-00
B-701732-00
• Fill Adapter Seal
B-775262-00
Test Pressure Gauge w/Tubing Adapter
0-4,1 bar/0-60 psig
B-775270-SV
• Female Fill Connector
B-775264-00
Reservoir Pressurizing Fixture0-6,9 bar/0-100 psig
B-701731-SV
8oz Oxygen Compatible Leak Detector
(SNOOP)
Gallon Oxygen Compatible Leak Detector
(SNOOP)
Erie Liter Meter, 0-8LPM
B-775272-00
B-778894-00
97200076
Companion Reservoirs
Tools and Accessories available from CAIRE
• Union, 5/8-in. Flare (2 per Transfer Line) B-775277-00
Female Top Transfill Line Adaptor
10678157
Dual Fill Adaptor TF&SF
10897958
Transfill Line Swivel
97404564
Super Flex LOX Transfer Line
m/6 FT
1.8
5/8” LOX Transfer Line w/Swvl Nuts
m/4 FT
1.2
5/8” LOX Transfer Line w/Swvl Nuts
m/6 FT
1.8
2.4
97406555
9713139
Erie Liter Meter, 6-15 LPM
10995620
Fluoro-Lubricant-2 oz Tube
CA200071
Lubricant - Krytox 240 AC Fluorinated
Grease
B-775239-00
Roller Base Assembly (Non-CE Marked)
10855678
5/8” LOX Transfer Line w/Swvl Nuts
m/8 FT
Rollerbase Assembly (CE Marked)
10585866
5/8” LOX Transfer Line w/Swvl Nuts 10 FT 10565161
Casters (set of 5; CE Marked)
14880379
Casters (set of 5; non-CE Marked)
14880361
5/8” LOX Transfer Line w/Swvl Nuts
m/12 FT
Shipping Carton C21/C31
10004081-SV
Shipping Carton C41
10004082-SV
3.0
9713119
10546550
10562411
Replacement Inline Filter, Male Transfer Line
CA400004
Adapter
Universal Adapter Kit
B-775461-00
• Male Flare Adapter
B-775342-00
• Female Flare Adapter
B-775418-00
• PB Fill Connector/Tee Assembly
B-775276-00
Reservoir Fill Connector Cover­­
B-777095-00
Companion Reservoir Technical Service Manual • PN 20559263 Rev B
43
Chart Industries, Inc.
Caire Inc., BioMedical Group
2200 Airport Industrial Dr., Ste. 500
Ball Ground, GA 30107
Ph 770-721-7700 • Toll Free 1-800-482-2473
Fax 770-721-7701
www.cairemedical.com
CAIRE Inc. reserves the right to discontinue its products, or change the prices, materials, equipment, quality, descriptions,
specifications and/or processes to its products at any time without prior notice and with no further obligation or consequence.
All rights not expressly stated herein are reserved by us, as applicable.
Chart BioMedical, Ltd.
Unit 2, Maxdata Centre
Downmill Road, Bracknell
Berks RG12 1QS, United Kingdom
Ph +44(0) 1189 367080 Fax +44(0) 1344 429224
Copyright © 2013 Chart Industries Ref 20559263 Rev B